Apparatus for producing shaped sections



w. R. DoDDs 2,544,447

APPARATUS FOR PRODUCING SHAPED SECTIONS Marchv 6, 1951 Filed Nov. 24, 1944 6 Sheets-Sheet 1 nventot Gttorneg March 6, 1951 W, R DODDS 2544,447

APPARATUS FOR PRODUCING SHAPED SECTIONS Filed Nov. 24, 1944 6 Sheets-Sheet 2 Gttorneg March 6, 1951 w. R. DoDDs APPARATUS PoR PRoDucING SHAPED SECTIONS 6 Sheets-Sheet 5 Filed Nov. 24, 1944 A mm l//W/A WW%\ MEP/ w A AW Y w A v Aw a \\\A\\ A W/ wlw A March 6, 1951 w. R. DoDDs 2,544,447

APPARATUS FOR PRoDUcING SHAPED SECTIONS Filed Nov. 24, 1944 6 Sheets-sheet 4 l 5.2L /g f4 /6 u m 79 /9 73 l C' J6 73a 73a a 6 6 l la? 5 5 1 a a l Isrwentor .56AM 5 mz/mmafzC/S 6C( Z Z/ (Itter-neg March 6, 1951 w. R. DoDDs 2,544,447

APPARATUS FOR PRODUCING SHAPED SECTIONS j 5V "5. l

Summer March 6, 1951 w. R. DoDDs APPARATUS FOR PRODUCING SHAPED SECTIONS Filed Nov.

6 Sheets-Sheet -atentecl Mar. 6, 195i UNITED STAT APPARATUS. FR .RDIG v spariti) sEcfrIoNs lWliian Rt dti, Paterson,` N.' J'., -a's'signor to' ooitiss=wrigiit corporation, a eorporation of Delaware Application November 24, 1f9i4`, seriaiivo. stanti My invention relates to an apparatus for pro diicing' shaped sections. 4

My invention has particular reference'to` a two*-V stage die press operative to produce a shaped section such, for example, as one forming a part of a propeller blade. In the rst stage, the punch shoe and the die block sectionsof the die press coact t partially shape a plate or blank and, in the second stage, the recited elements coact' to complete the shaped section.

Various other objects, advantages and features of my invention will loonie" apparent froi 'the followingv detailed description. p l n My invention resides in the die p'r'ss' utilizable for producing shaped' sections, comb tions and arrangements of the character hereinafter de scribed and claimed. i f For an understanding. of my invention, reference is to be had to the accompanying' drawings, in which:

Figure 1 is a bottom plan view showing the :nov`

able structure of the die press; y Fig 2 is a top plan View' showing the fixed structure of the die press;

.I Y I) Fig. 3 1s a transverse, vertical ysectional view direction of the arrows; V Y y Fig. 3a is a longitudinal, vertical sectional vi'v", partly in elevation, taken ori the line 3a`3c of Fig. 3 looking in the direction of the arrows; 1 Fig. 4 is a transverse, vertical seetijoiial view taken on Athe line 4-'4 of Fig; 2r looking in the direction of the arrows; v Fig. 4a is a longitudinal, vertical Sectional view, partly in elevation, taken on the lie l/-l' f Fig. 4 looking in the direction of the arrows; l

Figs 5 and' 6 are transverse, vertical s tional views slio'wingtiiel die piss diffrentV Operative' Stages? t 't t Fig. 6a isa longitudinal, vertical sectional view, partlyjin' elevation, vtaken-ofi theL line tez-26a" 6i Fig; 6 looking inthe direction o'f the' arrows: Fig. 'r is an end elevational view of`t`iiejdie-press-; Fig- 8` is a transverse; verticaisectioiiai view showing an operative stage" of" the` die=v` pres'sucor' respon'dig With --the stage illustrated Hy'Flgr 6 buttakenI ena differentA plane:

Fig. 8a is a transverse, verticaliy sectioa'lview, partlyA in. elevatiom. illustrating'-1:a` feature of? the inventiom. Y

taken on the line 3-3` of Fig.. 1 looking in the Fig; 9-is aplan viewvofaplateor blank destined tofform a shaped sectionV of a propeller blade;`

Figs.A 10, 11 and=-12 are'transverse, vertical secri tional views taken. onl the respective lines; I [1 -alu,

eiaiiii.- (on 782655 2 Fig. 13 is elevational vieirV showing the shapedsectio'j and 1 A Figs". 14, 15, 16 and 17v are'transverse, vertical sectional vievvs taken on the respective lines lli-' [5e-i5, {6i-'I6 and l'l'|'| f Fig. 13.

The disclosure of this application relates to 'the production of a shaped section which. as stated, vro'riir a pam' or a propeller blade. Ap; 'piioation s eriai` No; 564,980, filed Nov. 241944, vand novi/abandoned, relates to the formation of a propeller blade fron-1 a pair of such shaped sem-ifa Y InFwgs ,9" inclusive, I have shown a plate or biank P wiii except the tipe end thereofrus iestineo to forni one ioiieitudiriauy extending half of a ypr'optejiier bla-de. The plate P' is' synorrietrioai about itsloog'itudinaioenter line L. frire thickness thereof, throughout the ierigtnhwriioii willrform the propeller blade shank section, is unifor'nr and', at a `Sutalle location a-fa, the plate thickness startsite' decrease and does decrease eradu'aiiyirritii thejpi'ate tip is reached.

One face olf the plate P is plane eicept for a longitudinally extending gI-'ve'vd Which e'fitds from Vthe tipo'f the pitite toward the shank thereof and tiii'inats t sltbl l'caton Such tsi dl, trie provision or ,tiiisjeroove a' being optional. The otherrrfaoe ofjrtiie trate Pierrot piane since, as illustrated, it isde'n'd in part by adcentral i'lo la and fillets or tliic'kY sections' c at the ,respective plate edges. Between the rib b" and the respective niiets o, the' plate P` has uniform thickness througliiout any transverse section; l

The centrlrib b, with gradually'varying Width and varying? l'iigh't, iteidsfrom thev tip of the plate P toward the shank thereof and at a suitablelocation b l,1ner'ges or blends into the plate surface-. .As shown in Fig. 9, the rib b is vsymmetricalwith respect to the plate center line L ang-as indicated in Figs. l;1` and 12, the height o f said rib is greatest at said center linei Ongeach transverse side of the center line, the heighty of the ribb progressively decreases and, in ay symmetrical inanne'r,I merges into the plate surface.

The Vfillets c, at the respective edges ofthe plate" P, extend from the tip of the plate towardthe shank ther'eof-l and?. at suitable locations cl, the respective ufillets merge into the plate surface; The Avv'idtlii ofeachfillet c" graduallyincreases in a difre'ticinn extendig'from the tip of theplate toward the thereofand, in said direction, thefheight of s'aidllets c' progressively increases i int-accordancewwith increase in plate thickness.

rhe plate'y P may be produced in any suitable mannr. It may be- Inilledufrm'a plane sheet of metal but, preferably, it is produced by a forge rolling operation performed on a heated metal billet.

Referring to Figs. 2, 4, 4a. 5, 6, 6a, '7 and 8, I have shown a die press which comprises a fixed die shoe I having a longitudinally extending channel 2 in which a follower plate, ejectorbar or plunger 3 is disposed and movable vertically in the lower area thereof, `said plunger 3 resting upon a plurality of spaced depending plunger rods or pistons 4 freely movable in vertical passages 4a provided respectively therefor in housings 4b seated in the die shoe I. A pair of complementary backing blocks 5,-.5 are disposed in the channel 2 and in engagement with the respective inclined surfaces Ia of the die shoe I, said backing blocks 5, 5 seating upon vthe respective inclined surfaces 3a of the plunger 3. Each 'of the blocks 5 comprises 'a lateral extension 5a, these extensions facing eachother and serving as seats for the respective die block sections 6, 6 which jointly form the die block of the die press. As indicated in Fig. 4, the die block sections 6, 6 are secured to the respective backing blocks 5, 5 by screws 1.

As shown particularly in Figs. 2 and 7, each end of the die shoe I has a pair of spaced retaining plates 8 secured thereto by screws 9, or equivalent. A member I0 is secured to the interior surface of each plate 8 -by screws II or the like and these members Il] are disposed in non-binding relation in inclined slots formed respectively therefor in adjacent surfaces of the respective backing blocks 5, 5. Each plate 8 also comprises a vertical slot 8a and each slot 8a receives, in non-binding relation, a pin I2 carried by and projecting from the aforesaid plunger 3.

Referring to Figs. 1, 3, 3a and 5-8 inclusive, the die press is shown further as comprising an upper movable die shoe I3 which is secured to an upper support I4 by screws I5, or equivalent. Disposed in a longitudinal channel formed in the die shoe I3 is a punch plate I6 which is secured to the die shoe I3 by screws I'I, or equivalent. Seated in a longitudinal channel of the punch plate I6 is the base of the punch I8 which is flanked on its opposite respective sides by the gibs I9 secured to the punch plate I6 by screws 20, or equivalent.

Referring particularly to Figs. 1, 2, 3a, 4a and 6a. the aforesaid die block sections 6, 6 together with the punch I8 are all shown as having the same length which corresponds with the length of the aforesaid plate P. The die block sections 6 and 6, on the one handy, andthe punch I8, on the other hand, are complementary with respect to each other. When the punch I 8 is disposed in its final position, Fig. 6, said punch I8 together with the die block sections 6, 6 define a channel or pocket having the configuration which is to be finally imparted to the aforesaid plate P.

This configuration changes in a progressive manner from the shank of the plate to the tip thereof. As indicated in Figs. 3a, 4a, 6a` the punch I8 and the die block sections 6, 6 are adapted to form one end of the plate P into a hemi-cylindrical shank section which may extend as far as the line b-b, Fig. -13. Beyond the line b--b toward the right, Fig. 13, the punch I8 and the die block sections 6, 6 are adapted to impart non-cylindrical channel or U-shape to the plate P, the depth of the channel gradually increasing to a maximum adjacent the middle of the shaped plate and then gradually decreasing as the tip of the plate is approached. A typical cross-sectionindicative of this channel conguration is shown in Fig. 6. It will be understood, then, that the effective height of the punch I8 and the @die block sections E, 6 gradually increases to..a maximum and then gradually decreases, Figs'. 3a, 4a and 6a.

Referring to Fig. 8a, each of the aforesaid `housing passages 4a is indicated as having a pipe 2| communicating therewith, the pipes 2I being connected to a header 22 connected, in turn, to a suitable pump 23 which is supplied with hydraulic liquid from a tank 24. A pipe 25 communicates with the header 22 and is adapted to discharge hydraulic liquid into the tank 24 at or adjacent the top thereof. The pipe 25 includes a valve housing 26 having disposed therein a valvejll biased toward its seat, under predetermined pressure, by a spring 28 of such character thatlthe valve opens in response tothe ldevelop-- ment of a predetermined liquid pressure in that sectionv of the pipe 25 which communicates with the header 22.

Before proceeding with the die-shaping opf eration, operation of the pump 23 is initiated to cause a predetermined liquid pressure to be effective in the housings 4b to thereby maintain the plunger 3 in its upper position. As a result, the backing blocks 5, 5 together with the die block sections 6, 6 are held in their respective upper positions. plunger 3 carries pins I2 which are received in the respective slots 8a of the plates 8. As will be understood, this is a stop arrangement defining the limit of upward movement of the plumger 3.

In accordance with the invention, av plate P of the character illustrated in Figs. 9-12 inclu-v sive is heated to suitable forging temperature as 2250 degrees, more or less and, with the movable die shoe I3 elevated, said plate P is disposed in supporting relation, by the fillets c, c on the respective, elevated backing blocks 5 and 5, Fig. 4, in such manner that the plate groove a faces upwardly and extends longitudinally of the die press. When thus disposed, the plate center line L and the groove a coincide with a vertical plane which extends symmetrically with respect to the die block sections 6, 6.

f Thereupon, by suitable hydraulic, mechanical or drop forging means, not shown, the movable die shoe I3 is caused to descend whereby the lower edged surface IBa of the punch I8 comes into .engagement with the upper surface of the plate P at its longitudinal center line L,.such engagement. being initially effected when the punch I8, inthe zone of maximum punch height, enters the plate groove a. j, As ydownward movement of the die shoe I3 continues, engagement of the punch edged surface I8a with the plate P at its center line Lis effected progressively in opposite directions from vthe location of initial contact in theaforesaid zone` of maximum punch height. This action continues until; eventually, the edged surface I8a of the punch I8 engages the' plate P through# out the length thereof.

`During the describedl downward movement of the die shoe I3, the punch I8 causes the plate P, throughout the length thereof, vto progressively engage Ithe die block Asections 6, 6 at the respective surfaces 6a extending lengthwise thereof and then, throughoutthe plate length, to'progresfsively engage the curved die block sections 6b As hereinbefore stated, theV escaner- 5 `which also extend lengthwise j'o'f "the respectiwe die block=sections 6, B.

'InFig i5, the partially vshaped bla-nk shown after it has been `entirely withdrawn 'from fthe upper `surf-aces fof the backing vblocks H5 5 and from the 'upper 'surfaces of the -die vblock sections B, 6. .At this lsta'ge 'off the operation, the partially completed blank iis of LT1-configuration throughout its length Zand the bottom of the lil-section;

corresponding approximately with that 'of vthe edged surface ma ofthe punch lia. .ns .the parts fare positioned 'in Fig. 5, 'the horiizontalfs'urfaces of the fdie shoe lf3 and the pun-'c plate .i6 .have .just come :into engagement thehorizontal surfacesofthe backing-blocks' 5, 5 while the horizontal surfaces of 'the vgibs '159 and jpl-inch :i8 have just engaged the horizontal hun Iracesofthe hacking blocks .5 and the die block lsections 6., I6. Further, 'at this time, 'the respective vertical innersurfaces :i3d/of Siianges lfo'rin'ed on the movable die shoe l 3 .have com'e-into sliding engagement with the respective 'vertical Youter surfaces Ib of 'the iixed dieshoe l. Still lfurther, at this time, the plun'ger is lin 'its 'uppermost position where it remained during the described shaping operation.

As the iinal stage Aof the `shaping operation, the die :shoe I3 moves from the vpositionf'shown in Fig. l5 to that shown in Figs. 6, 6a, '7 and 8. Insodoing, the lbacking blocks 5 together withv the respective .die block :sections 6, 6. carried thereby vare moved 'downwardly and toward each other to form a channel or pocket in which the blank is given'its nalfshape, thelniovement last noted occurring by .reason 4of 4the fact tha-t the backing blocks E, 5 are VVin engagement with the` respective inclined surfaces la, la of the die shoe I.

Initiation of the last noted movement of'thedife shoe |3 causes downward `movement of the plunger 3. The pressure created'in the hydraulic s ystem by the descending plunger rods 54 causes the valve 2l, Fig. 8a.to open. Thereafter, 'wh-ile the backing blocks 5, 5 continue to apply downward pressure to the plunger Y3., the output oi 'the 'pump 23de by-passed to the tank 24 by'way of the ,pipe`2`5.

The above noted movementl -oif the die 'block sections 6, 6 toward each :other V causes them to coact with the punch i8 to complete the shaping operation-on the partially vconlple'ted blank.' In so doing, the aforesaid rib fb `of 'the plate TP fis shaped to form the edge el -of "the completed blade section B, this edge el being destined to form one edge of the complete propeller blade. In Fig. 16, I have shown approximately the maximum depth of the edge el. Toward the tip of the section B from the location of Fig. 16, the depth of the edge el decreases in a progressive manner and, similarly, the depth of said edge el progressively decreases in a direction extending' toward the shank of the section B from said location of Fig. 16. As stated above, the rib b merges into the surface of the plate P at the location bl, Fig. 9. Hence, this location is the zone wherein the edge el merges into the surface of the section B. When the shaping operation is completed, the bottom of the channel or U-section throughout the length thereof including the edge el, has nal curved contour as illustrated in Fig. 6a. In view of the foregoing, it will be understood that the blade section B has channel conguration and that the channel sides or walls branch from the curved edge el throughout the length th-erect. v Eurther, lthese channel fsides'or walls,

thGU'ghGut t'lie .length V0f Said. blade .Section B, terminate in'surfaces vsfl which occupy. a single plane fdispo'sedat right angles to fthe longitudinal plane of the blade section B.

As #shown on fthe --drawi-ngsl "the punch y'Hl comprise'san upper neck fsection 18h which extends 'from the tip fof said 'punch I8 -a distance corre- Spending -withthe llength of one of the "llets c. The neck section 48o is symmetrical With respect 'to a vertical plane extending longitudinally through the central partei vthe punch l8-. 'The aforesaid 'fn'ec'k section [8b denes :channels at the respective opposite sides `of the -p'unch v'l wlicrhhave `dimensions corresponding with those of the respective llets c, c. As the die block sections fs., f6 approach and 'reach the i-inal position shown innig. "6, the metal "forming the duets c, c, v'is 'shifted transversely whereby said 'fillets c, c areremoved from 'the 'exterior surface ofthe blank 'and formed `on the interior surface 'of fthe completed blaiik` as indicated at Ycl and ci, Figs. 15, 16 and 17, the respectivechannels of the :neck section I`8b being provided'w'ith this 'end in View.

Between 'the edge ei vof vthe completed blade 'section'B and the lillets rcl and Ici, the walls have uni-'form thickness excep't'where the Wall thickness 'gradually increases as defined by 'smooth curves, Figs. 15, Y16 land 41'7, which lmerge into the 'edge e'l and Viilflets, c1, cl respectively.

After completion of the vinal shaping operation, application -of-ffor'ce to the diie shoe 'l lis reversed with'the *result thatsaid die shoe returns tothe 'position thereof vshown in Alhg. '3. -As soonas "Such return 'movement-of the die 'shoe i3` -is initiated, 'the pressure previously created in the hydraulic `systemby the 'descending plunger rods Lis discontinued. As a result, the valve 27 closes 'and the pump 423 becomes effective to elevate the plunger Btogether with the thereby-carriedback- 4.blocks 5 and v5, theblock sections 6 and '6 and the vshaped blade `section B which 'is disposed betweenthe'l'atter.

'Referring to Figs. lf3-"17 inclusive, I have shown the completed blade section B which is free of propeller blade .pitch and which is shaped, in 'accordance with the invention, 'as describedlabo've. The blade section B comprises the'heini-cyl'indri'- cal shank section .sl which may extend as far 'as the line ZJ-b, Fig. I3. Beyond the line 'Z2-b, toward the right, theblade section vB has 'non-cy- .lindrical 'channel configuration, the `depth of the channel gradually 'increasing to a maximum extentat about the location of the ,transverse section, Fig. 1'6, and 4Ithen gradually decreasing `as the tip of thebla'de 'section Bis approached. The edge el together with the changing heights thereof are illustrated in Figs. 15, 16, 17 as are the inner llets cl, cl. As clearly appears, the exterior surfaces of the blade section B have suitable airfoil conguration and, as indicated in Figs. 13-17 inclusive, there is a longitudinally extending plane A with respect to which the exterior surfaces of said blade section B are symmetrically disposed. This is true by reason of the fact that any line extending perpendicular to the plane A and intersecting one Vside of said shaped section has the same length, between the plane A and the point of intersection, as the length of a straight-line extension of said line between said plane A and the point of intersection thereof with the opposite side of said shaped section.

The members I0, hereinbefore referred to, are disposed parallel with respect to the respective inclined surfaces la of the die shoe l. During movement of the backing blocks 5, 5 as described above, they move freely with respect to the mem.- bers I which, as stated, are secured to the re;- spective plates y3. When the die press is of the vertical type as illustrated, the ymembers l0 have no particular function and, hence, may be omitted. However, when-the die press is ofthe horizontal type, the members I0 serve to lretain the backing blocks 5, in their respective operative positions.

v` `It will be understood kthat the flanges of the movable die shoe I3 having the described inner surfaces I3a coact with the upper ends of the fixed die shoe I to effectively prevent the latter from spreading during the nal shaping `opera tion. A particular advantage of the invention re. sides in the fact that thedescribed die shaping or forging operation results in the production of smoothI` radii at the bottom of the channel'de- -f ned by the blade section B and at the margins of the fillets cl, cl. This is highly desirable in the propeller blade art.

It shall be understood that the invention is not to be limited to a shaping operation performed on a plate of the character illustrated in Figs. 9-12 inclusive. Obviously, plates of other different shapes may advantageously be shaped or forged in accordance with the invention.

While the invention has been described with respect to the formation of a shapedsection B as long (except for the tip) as the propeller blade to be produced, it shall be understood that the invention is not to be thus limited. If desired, for example, a pair of die presses Imay be provided, one of these forming a part of the disclosed shaped section and another forming the other part thereof.

It will be understood that the shaped section B is produced without propeller blade twist. It will also be understood that the die press may be of such character that it forms a complete ,halfsection of the propeller blade including ythe tip.

While the invention has been described with respect to a certain particular preferred example y it is intended therefore in the appended claims 8f Shaped blank, said fixed member having an elongated longitudinally extending channel, the longitudinal side walls of which extend in converging directions toward the inner part of said channel, a pair of elongated die blocks movably mounted insaid channel and movable toward and from each other along said converging sides in response to 'movement thereof into and from said channel, fluid pressure operated means tending to move saiddie blocks partly from said channel so as to cansefsaid blocks to rise from the channel and to separate from each other, the protruding ends of said die blocks being adapted to support a blank workpiece, an elongated blade-like punch constituting an integral unit carried by the movable die member, said punch being movable toward and between said die blocks, said movable die member. after movement of said punch between said die blocks engaging said protruding die blocks and moving them into said channel against said pressure means and thereby causing said die blocks to move toward each other so as substantially to enclose the aforesaid punch blade, and flange elements rigid with said movable die member engageable with the outer edges of said fixed die member as said movable and xed die members are moved toward one another, whereby the xed die member, having said channel therein, is'constrained against lateral displacement by said flange elements as lateral stress is developed therein during die closing by the said movement of said die blocks toward one another.

WILLIAM R. DODDS.

REFERENCES CITED The following references are of record inthe file of this patent:

UNITED STATES PATENTS Number Name Date 1,150,479 Zwiker Aug. 17, 1915 1,502,722 Hill July 29, 1924 .1,561,556 McMahon Nov. 17, 1925 1,664,904 Stanek Apr, 3, 1928 1,766,098 Booth June 24, 1930 1,792,224 Johnson Feb. 10, 1931 1,823,557 Bowen Sept. 15, 1931 1,823,961 Vogelsang Sept. 22, 1932 1,880,454 Klocke Oct. 4, 1932 1,938,915 Leighton Dec. 12, 1933 2,231,772 Nelson Feb. 11, 1941 2,295,852 LeJeune Sept. l5, 1942 2,343,082 Proctor Feb. 29, 1944 2,350,884 Ernst June 6, 1944 2,473,673 Bell June 21, 1949 

